Panel forming machine

ABSTRACT

A panel forming machine in which two sheets of material such as sheet metal are fed from supporting arbors through die-forming means, spray means then sprays material into the space between the sheets of material, and dies then hold the sheets in the desired relationship while the material expands and gels.

O United States Patent [191 [111 3,777,347

McCorvey Dec. 11, 1973 [54] PANEL FORMING MACHINE 3,401,442 9/1968 Matheny 29/208 D [76] Inventor: Raymond S. McCorvey, P. O. Box

405, Houston, Tex. 77547 Primary Examiner-Thomas H. Eager [22] Filed, Aug 21 1972 Att0meyJoe E. Edwards et a].

21 Appl. No.: 282,562

[57] ABSTRACT .fizgfii/iggoAo A panel forming machine in which two sheets of mate 58] APZOO B rial such as sheet metal are fed from supporting arbors le 0 care R 208 200 through die-forming means, spray means then sprays material into the space between the sheets of material, 56 R f C1 d and dies then hold the sheets in the desired relation- UNITE]; 5:2 :28 I ZTENTS ship while the material expands and gels. 3,399,445 9/1968 Carroll 29/200 A 5 Claims, 6 Drawing Figures Pmimmac 1 1 ms SHEET 1 [IF 2 PATENTEUUEITH 1975 3771347 SHEET 2 or 2 /F A?! 2/: PM Z/a PANEL FORMING MACHINE This invention relates to a machine for forming insulated panels and more particularly to a machine for continuously forming an insulated panel having two spaced sheets of material with expanded material such as plastic therebetween.

Insulated panels in the past have taken two forms. Inc

one form, a sheet of material has an expansible material poured thereon and permitted to expand to give a panel having a finished surface on one side and insulation material on the other side. In the second form, a sandwich of insulating material has been provided by forming two separate sheets of material and a sheet of insulation material. The three sheets are then adhered together to provide a panel finished on both sides with the insulation material therebetween. Both of these known processes are non-continuous in nature and expensive. In the working of sheet metal, it is known to form two sheets of material into the desired cross-sectional shape and crimp the two sheets of material together, leaving a hollow space therebetween. This has been done in a continuous manner with the desired lengths of material cut from the continuously formed product. The space between the two sheets of material in this product has been empty.

It is an object of this invention to continuously form a panel of two sheets of material having a sheet of insulation material therebetween in which sheets of material are formed into the desired configuration and are then held together by the insulating material which is formed in place between the sheets of material.

It is another object of this inventionto continuously form a panel in which the two external sheets are formed into their desired cross-sectional configuration in a continuous manner, insulation material of an expansible type is placed between the two sheets of material, and the two sheets of material held in the desired relationship to each other while the insulation material expands to form a continuous panel which may thereafter be cut into the desired lengths.

Another object is to fonn a panel as in the preceding object in which the two sheets of material are formed in suitable dies which are spaced slightly from each other and the insulating material is sprayed or injected into the space between the two sheets before they reach the holding section of the apparatus.

Other objects, features and advantages of the invention will be apparent from the drawings, the specification, and the claims.

In the drawings wherein like numerals indicate like parts, and wherein an illustrative embodiment of this invention is shown,

FIG. 1 shows schematically a panel forming apparatus constructed in accordance with this invention;

FIG. 2 is a view along the lines 2-2 of FIG. 1;

FIG. 3 is a view along the lines 3-3 of FIG. 1;

FIG. 4 is a view along the lines 4-4 of FIG. 1;

FIG. 5 shows a different type of panel constructed on a machine similar to that shown in FIG. 1; and

FIG. 6 shows a structural member as distinguished from a panel formed on a similar machine.

First and second arbors l0 and 11 are provided to support rolls of material 12 and 13 respectively. These rolls of material may be sheet metal, plastic, cardboard, or any other desired material. One face of the sheet material may be finished to simulate wood or other type of surfaces if desired.

The sheet material feeds into the first and second forming dies indicated generally at 14 and 15 respectively and driven by motor 16. These dies may take any conventional shape to form the two sheets of material 17 and 18 into the desired cross-sectional configuration.

The forming dies 14 and 15 are arranged in generally parallel relationship closely adjacent to each other, so that the formed sheets of material leave the forming dies traveling in the same general direction and spaced slightlyfrom each other. The spacing in relationship to the forming dies 14 and 15 is not critical, except that a space must be provided between the sheets of material 17 and 18 at some point so that the spray means 19 (FIG. 2) can deposit insulation material onto one or more of the sheets 17 and 18.

Insulation material is provided from a convenient source not shown through a plurality of lines 21 to the spray means 19 where it is mixed and projected out through the spreader 22.

The insulation material may be any desired material which will expand and occupy the space between the two sheets of material to provide insulation. Polyurethane, in combination with a suitable catalyst and a fire-proofing material, is preferred, as it has good expansion and insulation characteristics, and also is a good adhesive and will adhere to the two sheets of material 17 and 18. If desired, a filler having a greater expansion radio than polyurethane, may be used. Other plastics, such as polystyrene, may also be used, as may any desired expansible material with or without filler which will provide good insulation characteristics.

Preferably polyurethane material is delivered through line 21a and a suitable catalyst through a second line 21b to the spray means 19 where they are mixed before being introduced into the spray tube 22. Preferably, a third line 21e is also utilized and delivers to the spray means a fireprooting material which is mixed in the spray means l9 'to give a fire proof polyurethane insulation material. The spray tube 22 should be made of adisposable material so that a new spray tube may be provided each time the system is shut down, thus avoiding the necessity of cleaning the spray tube *to remove the polyurethane which sets up very rapidly.

Whilethe insulation material could be delivered to one or both of the sheets of material 17 and 18, it is preferred to spray it onto the lower sheet 17 as illustrated in FIG. 2. The polyurethane material is normally quite viscous and flows slowly. This permits the angling of the sheet of material relative to the horizontal so that the two forming dies may be arranged horizontally for convenience and so that both sheets of material 17 and 18 may be bent slightly toward each other as they leave the forming dies 14 and 15.

After the insulation materialis deposited on sheet 17, the two sheets 17 and 18 are brought together and pass through a plurality of holding die means indicated generally at 23 and 24. These die means are driven by suitable motors 25 and 26, respectively.

As shown, the holding die means hold the two sheets of material against movement away from each other while the expansible gelable material such as polyurethane, expands and gels in the space between dies.

One of the series of die means is shown in FIG. 4 and includes the lower die roller 27 which has a continuous cylindrical periphery to support the lower sheet of material 17 which is generally flat but turned up on each side. The upper die 28 is provided with several lands and grooves to conform to the shape of the upper sheet of material 18.

If desired, a suitable shoulder such as 29 may be provided to prevent lateral movement of the turned-in sheets of material under the force of the expanded plastic. In like manner, a bevelled surface 31 prevents opening of the crimped edge of the panel.

By comparison of the panels shown in the FIGS. 3 and 5, it will be noted that the panels may be crimped or not as desired.

If it is desired to crimp a panel such as shown in FIG. 3, the first section of holding dies 23 will perform the dual function of holding the sheets of material 17 and 18 in the desired relationship and crimping one or more of the edges of the sheets of material if desired.

The insulation material is illustrated to still be in liquid form in FIG. 3 which is between crimping dies 23 and holding dies 24. This will depend upon the speed of the machine and the place at which the expansible material is injected. In FIG. 1 the material is shown as being injected at a midway point. Thy dotted tubes 22 illustrate that the spray means may be moved to other positions, depending upon the material used and the speed at which the apparatus is run to give the insulation material adequate time to generally spread over the sheet material 17 and to make sure that the material does not completely expand until after the sheets of material 17 and 18 are within ;the area of the crimping holding die 23.

The insulation material may expand toits fully expanded condition at any time after the sheets of material 17 and 18 reads the holding crimping die 23. Preferably, the crimping is completed prior to any substantial expansion of the insulation material, and the expansion of the insulation material and its final gelling occurs within the holding dies24.

A flying or'traveling cutter indicated generally at 32 is positioned to cut off sections of the panel in the desired lengths after they leave the holding dies 24.

In FIGS. and 6, other forms of panel are shown to illustrate that any desired configuration of panel may be made. The panel indicated in FIG. 5 is not crimped on either side and is provided with channels in opposite sides to assist in its installation in the building.

In FIG. 6 there is shown a structural member manufactured in the same manner which may be for example 4 inches by 4 inches in cross-section and which may be utilized as a structural member of a building.

From the above it will be seen that the objects of this invention have been attained. An apparatus has been provided for continuously forming a panel of two sheets of material which begin as flat strips of material and are formed into the desired cross-sectional configuration. An expansible material is injected and while this material is expanding and gelling into a final insulation shape having many voids therein the outside sheets of the panel are held against movement away from each other so that the final panel form will be continuous and the configuration of the panel will be constant even though it has been subjected to the expansion of the insulation material.

It is noted hereinabove that'preferably the insulation material is one which also has good adhesive characteristics so that it will adhere to the two panels and hold the two panels in the desired configuration.

The foregoing disclosure and' description of the invention is illustrative and explanatory thereof and various changes in the size, shape and materials, as well as the details of the illustrated construction may be made within the scope of the appended claims without departing from the spirit of the invention.

1 claim:

1. Apparatus for continuously forming an insulated panel comprising,

first and second arbors for supporting first and second rolls of sheet material respectively,

first and second forming die means for forming the cross-sectional shape of the first and second rolls of material respectively,

said first and second die means arranged such that the formed sheets of material leave the die means traveling in the same general direction and spaced from each other,

spray means for spraying expansible gelable material into the space between the two sheets of material after they leave the forming dies, said expansible gelable material accumulating on at least one of said sheets of material as the sheets move past the spray means;

a plurality of holding dies arranged in tandem and receiving the two sheets of material and holding said two sheets of material against movement away from each other while the expansible gelable material expands and gels.

2. The apparatus of claim 1 wherein the holding die means which is adjacent the forming die means crimps one or more sides of the two sheets of material together.

3. Apparatus of claim 1 in combination with a movable cutter means positioned to cut lengths of panel from the continuous sheet after the sheet leaves the holding die means.

4. Apparatus for continuously forming an insulated panel comprising,

first and second arbors,

first and second rows of sheet material on said arbors;

first and second die means forming the crosssectional shape of the first and second rows of sheet metal respectively,

said first and second die means arranged such that the formed sheets of material leave the die means traveling in the same general direction and spaced from each other,

spray means for spraying expansible, gelable plastic material into the space between the two sheets of metal after they leave the forming dies,

said plastic material accumulating on at least one of said sheets of metal as the sheets move past the spray means,

a plurality of holding die means arranged in tandem receiving the two sheets of metal and holding said two sheets of metal against movement away from each other while the plastic material expands and gels.

5. The apparatus of claim 4 wherein the plastic material is polyurethane. 

1. Apparatus for continuously forming an insulated panel comprising, first and second arbors for supporting first and second rolls of sheet material respectively, first and second forming die means for forming the crosssectional shape of the first and second rolls of material respectively, said first and second die means arranged such that the formed sheets of material leave the die means traveling in the same general direction and spaced from each other, spray means for spraying expansible gelable material into the space between the two sheets of material after they leave the forming dies, said expansible gelablE material accumulating on at least one of said sheets of material as the sheets move past the spray means; a plurality of holding dies arranged in tandem and receiving the two sheets of material and holding said two sheets of material against movement away from each other while the expansible gelable material expands and gels.
 2. The apparatus of claim 1 wherein the holding die means which is adjacent the forming die means crimps one or more sides of the two sheets of material together.
 3. Apparatus of claim 1 in combination with a movable cutter means positioned to cut lengths of panel from the continuous sheet after the sheet leaves the holding die means.
 4. Apparatus for continuously forming an insulated panel comprising, first and second arbors, first and second rows of sheet material on said arbors; first and second die means forming the cross-sectional shape of the first and second rows of sheet metal respectively, said first and second die means arranged such that the formed sheets of material leave the die means traveling in the same general direction and spaced from each other, spray means for spraying expansible, gelable plastic material into the space between the two sheets of metal after they leave the forming dies, said plastic material accumulating on at least one of said sheets of metal as the sheets move past the spray means, a plurality of holding die means arranged in tandem receiving the two sheets of metal and holding said two sheets of metal against movement away from each other while the plastic material expands and gels.
 5. The apparatus of claim 4 wherein the plastic material is polyurethane. 